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Troubleshooting

B 5-1

Part 1102698

−

2019 Nordson Corporation

Section B 5

Troubleshooting

WARNING:

Allow only qualified personnel to perform the following tasks.

Follow the safety instructions in this document and all other related

documentation.

These procedures cover only the most common problems that you may

encounter. If you cannot solve the problem with the information given here,

contact your local Nordson representative for help.

No.

Problem

Page

Pump fails to start or stops while operating and fails to

restart

B 5-2

Pump double strokes at one end of stroke and will not

change direction

B 5-3

Excessive or constant air leakage from air motor or air

valve

Pump strokes irregularly when spray device is

triggered

B 5-3

Pump operates but flow is restricted, or pump surges

B 5-4

Pump fails to siphon coating material

B 5-4

Pump continues to operate even after drain and

circulation valves are closed and spray devices are

shut off

B 5-5

Pump does not stroke when circulation valve opened

B 5-5

Solvent cup overflows often

B 5-5

10.

Fading or narrowing spray pattern

B 5-6

11.

Spray pattern has tails of unatomized coating material

at the outer edges

B 5-6

Содержание PermaFlo 815

Страница 1: ...03 19 NORDSON CORPORATION AMHERST OHIO USA Check http emanuals nordson com finishing for the latest version This document is subject to change without notice For parts and technical support call the I...

Страница 2: ...opyright Original copyright date 2008 No part of this document may be photocopied reproduced or translated to another language without the prior written consent of Nordson Corporation The information...

Страница 3: ...aced by 1102698a Hydraulic Section Repair procedures updated to include alignment tool 02 7 12 Added Type F self adjusting packings pump 1602026 03 10 16 Updated gauge port 04 11 18 Update self adjust...

Страница 4: ...Change Record ii Part 1102698 07 E 2019 Nordson Corporation...

Страница 5: ...lic Section Kits A 1 4 Recommended Spare Parts A 1 4 Adhesives Sealants and Lubricants A 1 5 Solvent Chamber Fluid A 1 5 Solvent Chamber Fluid Guide A 1 5 Options A 1 6 Safety B 1 1 Introduction B 1 1...

Страница 6: ...roduction C 1 1 Tools and Materials Required C 1 1 Guidelines for O ring and Seal Replacement C 1 2 Coupling Removal and Replacement C 1 2 Coupling Removal C 1 2 Coupling Replacement C 1 3 Air Motor R...

Страница 7: ...ard Packing Assemblies C 2 7 Type F Standard Packing Assemblies C 2 7 Type F Self Adjusting Packing Assemblies C 2 8 Type D Self Adjusting Packing Assemblies C 2 8 Changing Packing Gland Type C 2 9 Pa...

Страница 8: ...ing Kit D 2 8 Type F Standard Packing Kit D 2 8 Type L Standard Packing Kit D 2 8 Type D Self Adjusting Packing Kit D 2 9 Type F Self Adjusting Packing Conversion Kit D 2 9 Type F Self Adjusting Packi...

Страница 9: ...witching between packings Solvent Chamber Fluid Solvent Cup 1023813 standard Type U F L packings 1085475 self adjusting Type D or F packings see Note Solvent Chamber Fluids 248831 Type S 1 Quart for s...

Страница 10: ...pump This manual covers the following pumps 1024648D and above Type U packings 1065204A and above Type F packings 1085453A and above Type D packings 1602026A and above Type F self adjusting packings F...

Страница 11: ...8 16 Liters gallons cycle 0 51 0 136 1 Cycle 2 strokes 1 up and 1 down High Pressure Hose WARNING Use Nordson or equivalent nylon or PTFE fluid hoses with electrical continuity between fittings Fluid...

Страница 12: ...usting D NOTE A Standard packings can be used in 1024648 and 1065204 pumps B Self adjusting packings can be used in 1085453 pump C To convert a pump using standard packings to use self adjusting packi...

Страница 13: ...he following parts in inventory to avoid unplanned downtime Quantities listed support a single pump Adjust order quantities based on the number of pumps in service Part Description Quantity Note PACKI...

Страница 14: ...e S pump chamber one quart 900255 FLUID type K pump chamber one quart 140029 FLUID type T pump chamber one quart 244854 FLUID type Q concentrate 2 6 fluid ounce makes one gallon Solvent Chamber Fluid...

Страница 15: ...packing Type L PermaFlo 815 D 1089172 KIT packing Type F PermaFlo 815 self adjusting D 973391 BUSHING reduction 3 4 x 3 8 in NPT steel zinc E NOTE A An air lubricator is not required All elastomers in...

Страница 16: ...are familiar with all relevant safety rules and regulations and are physically capable of performing their assigned tasks Intended Use Use of Nordson equipment in ways other than those described in th...

Страница 17: ...not restart the equipment until the problem has been identified and corrected S Obtain and read Safety Data Sheets SDS for all materials used Follow the manufacturer s instructions for safe handling a...

Страница 18: ...stance to infection bacterial growth will flourish The treatment that doctors recommend for an injection injury to the hand includes immediate decompression of the closed vascular compartments of the...

Страница 19: ...Under pressure these solvents can react with aluminum and explode causing injury death or property damage Halogenated hydrocarbon solvents contain one or more of the following elements Element Symbol...

Страница 20: ...aid must be immediately obtained S COMPONENT RUPTURE This system is capable of producing high pressure Please refer to the data plate on the hydraulic section To avoid rupture and injury do not operat...

Страница 21: ...Safety B 1 6 Part 1102698 07 E 2019 Nordson Corporation 1 3 2 Figure B 1 1 Safety Labels 1609843 Figure B 1 2 ATEX Label...

Страница 22: ...indicates the air motor cylinder diameter and the fluid to air ratio 815 designates an 8 inch 203 mm air cylinder and 15 1 ratio 830 designates an 8 inch 203 mm air cylinder and 30 1 ratio The hydraul...

Страница 23: ...irculating System Operation In a dead end system the pump starts when air pressure is applied It continues to operate until the fluid pressure in the system equals the pressure the pump can produce wi...

Страница 24: ...ir motor 2 Air valve 3 Air valve spool 4 Lower cylinder head 5 Connecting rod 6 Air piston 7 Upper cylinder head 8 Mufflers 9 Actuator assembly air pilot valve 10 Valve assembly air pilot valve 11 Hyd...

Страница 25: ...filter regulator and gauge in the air supply line ahead of the pump The air filter should have a 40 micron or smaller screen Refer to Section D1 Air Motor Parts for the optional Air Motor Accessory ki...

Страница 26: ...iding of Nordson warranties WARNING If any component of the high pressure fluid system has a maximum working pressure less than the pump s install a pressure relief valve in the hydraulic system set t...

Страница 27: ...and an air filter regulator gauge package Fluid Connections Refer to Section A1 Quick Reference for siphon and high pressure hose recommendations and Section D2 Hydraulic Section Parts for optional s...

Страница 28: ...mm Fasteners 3 4 in NPTF High Pressure Fluid Outlet Port 1 in NPT Siphon Port 286 mm 11 25 in Overall length will increase if optional circulation valve valve kit is installed 918 mm 36 14 in Figure...

Страница 29: ...alling Use an air dryer and filter the air to 40 microns or better S The air drop to the pump should be plumbed from the top of the plant air line Install a drop leg and drain valve at the bottom of t...

Страница 30: ...Figure B 3 4 Typical Dead End System Connections and Components 1 Plant air line 2 Drop leg 3 Drain valve 4 Air shut off valve self relieving 5 Filter Regulator Gauge 6 Air hose 7 Coating supply 8 Sip...

Страница 31: ...t air line 2 Drop leg 3 Drain valve 4 Air shut off valve self relieving 5 Filter Regulator Gauge 6 Air hose 7 Coating supply 8 Siphon rod and strainer 9 Siphon hose 10 High pressure fluid hose 11 Flui...

Страница 32: ...ic poisoning or death WARNING Do not remove any sheet metal covers from the pump while it is operating Moving parts under the covers could cause an injury This section covers the following procedures...

Страница 33: ...ent chamber fluid for your application Refer to Section A1 Quick Reference for compatibility information and part numbers See Figure B 4 1 Fill the solvent cup to within 12 mm 1 2 in of the top with s...

Страница 34: ...onnections are tight S air filter 2 has been drained S compressed air is available to run the pump S drain rod 10 is in a waste container 11 circulating systems only S pump coating material supply and...

Страница 35: ...heater outlet Circulate coating material through the heater until it is at desired temperature before spraying parts NOTE Overheating coating materials can cause cavitation in the pump if the solvent...

Страница 36: ...stem Circulating System 3 2 3 7 Figure B 4 2 Typical Dead End and Circulating System Components 1 Air shutoff valve 2 Air filter regulator gauge 3 Solvent cup 4 Coating supply 5 Siphon rod and straine...

Страница 37: ...ber fluid in the solvent cup 3 The solvent chamber fluid should be 12 mm 1 2 in from the top Add more solvent chamber fluid as needed NOTE Coating material leaking past the upper packing gland will di...

Страница 38: ...operating and fails to restart B 5 2 2 Pump double strokes at one end of stroke and will not change direction B 5 3 3 Excessive or constant air leakage from air motor or air valve 3 4 Pump strokes ir...

Страница 39: ...e Make sure all hose connections to the air valve are tight Spool in air valve stuck in middle position Set the input air to 40 psi Open and close the input air ball valve to give the air valve quick...

Страница 40: ...leaking O rings sealing air valve to cylinder heads leaking Check for air leaking at the air valve to cylinder head joint Replace the O rings if they are leaking O rings sealing cylinder to cylinder...

Страница 41: ...or fluid tip size Reduce the number of spray devices connected to the pump Reduce the circulation rate 6 Pump fails to siphon coating material Blocked siphon strainer screen rod or hose Check and cle...

Страница 42: ...lation valve in place of the return hose 7 Apply compressed air to the circulation valve If air bubbles from the siphon rod replace the circulation valve needle and seat Leaking ball check valve Rebui...

Страница 43: ...pattern has tails of unatomized coating material at the outer edges Low hydraulic pressure or partial blockage in system Increase the air pressure Flush the system with a compatible cleaning solution...

Страница 44: ...otor rebuild S Air valve rebuild NOTE Part numbers in illustrations match the item numbers in Section D1 Air Motor Parts Lettered parts are part of the hydraulic section and are shown in Sections C2 H...

Страница 45: ...cause it to leak Coupling Removal 1 Stop the air motor in the middle of a stroke Shut off the air supply to the pump and disconnect the air supply hose from the air valve 2 See Figure C 1 1 Loosen the...

Страница 46: ...ws 32 with a 3 16 in hex wrench to 10 2 1 NSm 90 10 in lb Air Motor Rebuild Air Motor Removal 1 Stop the pump in the middle of a stroke 2 Shut off the air supply to the pump and relieve the remaining...

Страница 47: ...oved and replaced without disassembling the air motor NOTE If you have the cartridge type air pilot valves refer to manual 1032967 available on http emanuals nordson com finishing 4B 4C 4D 5A 5B 5C Ap...

Страница 48: ...e the four 1 4 20 x 1 375 in socket head screws A from the air valve with a 3 16 in hex wrench then remove the air valve from the cylinder heads Refer to Air Valve Rebuild in this section 5 Remove the...

Страница 49: ...se it to leak 4 Lift the air piston 22 up off the lower cylinder head 16 carefully pulling the connecting rod 21 through the U cup seal 17 and out of the lower cylinder head 5 Remove the four socket h...

Страница 50: ...head before installing Loosen Left hand threads Turn clockwise to loosen counterclockwise to tighten Figure C 1 5 Air Motor Disassembly 1 Long hex head screws 2 Upper cylinder head 14 Large O rings 15...

Страница 51: ...terclockwise left hand threads onto the connecting rod 21 until the piston contacts the shoulder at the bottom of the connecting rod threads 2 Install the flat washer 23 on the socket head screw 24 an...

Страница 52: ...e lips of the seal facing up toward the air pressure as shown in the cutaway drawing 3 Install the backup plate 18 and secure it with the four socket head screws 19 and lock washers 27 18 16 17 19 18...

Страница 53: ...air piston 22 and the inside diameter of the cylinder 15 2 Insert the end of the connecting rod through the lower cylinder head 16 and carefully through the U cup seal 3 Slide the cylinder over the a...

Страница 54: ...4 NSm 30 4 ft lb 1 20 22 2 15 Apply MagnaLube G or equivalent PTFE grease to connecting rod rubber part of piston and ID of cylinder before installing Tighten to 40 5 4 NSm 30 4 ft lb Do not over tigh...

Страница 55: ...four large O rings 26 with PTFE grease and install them in the grooves in the side of the air valve 4 Hook the mufflers 28 into the slots in the front of the air valve and swing the mufflers back aga...

Страница 56: ...age C 1 2 5 Connect the air hose to the air valve 6 Connect the ground clamp to a true earth ground 7 Supply compressed air to the pump and check the air motor operation Check for air leaks Air Valve...

Страница 57: ...r threads before installing Figure C 1 12 Air Valve Rebuild 1 Socket head screws 2 End caps 3 Large O rings 4 Brass sleeves 5 Small O rings 6 Shuttle valve 7 Valve body 8 T seals 9 Aluminum sleeves 10...

Страница 58: ...em numbers in Section D2 Hydraulic Section Parts Lettered parts are part of the air motor Tools Required The following tools are needed to repair the hydraulic section S Small and large adjustable wre...

Страница 59: ...he U cup seal and cause it to leak Coupling Removal 1 Stop the air motor in the middle of a stroke and disconnect the air supply hose from the air valve 2 See Figure C 2 1 Loosen the two set screws B...

Страница 60: ...e pump from its mounting Disassemble and assemble the hydraulic section on a bench using a rubber mallet arbor press and soft jawed vise Preparation 1 Flush the hydraulic section with a compatible sol...

Страница 61: ...through the pressure housing If no rubber mallet is available use a hammer and wood block on the end of the plunger to protect it from damage 7 Remove the pressure housing 8 from the soft jawed vise 8...

Страница 62: ...ing Standard Self Adjusting 2 Upper Packing Lower Packing Figure C 2 3 Hydraulic Section Disassembly 1 Solvent cup 2 Packings 3 Upper housing 4 Plunger 5 Ball small 6 Pressure ball seat 7 O rings whit...

Страница 63: ...does not leak from the seats you do not need to replace the seats or balls Packing Assemblies Packings are available only as kits The kits contain both upper and lower packing assemblies Type U Stand...

Страница 64: ...g Leather V ring UHMWPE V ring Leather V ring UHMWPE V ring Leather V ring Lower Male Adapter Figure C 2 5 Type L Standard Packing Assemblies Type F Standard Packing Assemblies Lubricate the new V rin...

Страница 65: ...ure C 2 7 Type F Self Adjusting Packing Assemblies Type D Self Adjusting Packing Assemblies Lubricate the new V rings with O ring lubricant Assemble the packings as shown in Figure C 2 4 NOTE The stac...

Страница 66: ...self adjusting packings to standard packings you must order and install the solvent cup and pressure ball check kit listed for the Type U or F hydraulic section in Section D2 Hydraulic Section Parts...

Страница 67: ...the small ball 5 into the pressure ball seat between the cage ears 7 Apply thread lock adhesive Loctite 242 onto the threads of the pressure ball seat 6 8 Screw the pressure ball seat into the plunge...

Страница 68: ...1 Part 1102698 07 E 2019 Nordson Corporation 4 5 6 7 8 9 7 Figure C 2 10 Pressure Housing and Plunger Assembly 4 Plunger 5 Ball small 6 Pressure ball seat with packings 7 O rings white PTFE 8 Pressure...

Страница 69: ...lubricant Insert the coupling end of the plunger 4 into the bottom of the upper housing 3 and push it through the upper packing 3 Thread the pressure housing 8 into the upper housing 3 and tighten snu...

Страница 70: ...ring lubricant Install the PTFE O ring 13 siphon ball seat 12 large ball 11 and cage 10 into the siphon housing 3 Lubricate the threads of the pressure housing and the siphon housing with O ring lubri...

Страница 71: ...4 NSm 100 10 ft lb 2 Secure the upper housing 3 to the pump mounting surface 3 Tighten the entire hydraulic section using the large hex nut on the siphon housing Tighten securely 15 3 16 Customer supp...

Страница 72: ...and Type F self adjust packings by tightening the solvent cup all the way down until it bottoms out Use the tightening ports on the solvent cup with a spanner wrench or pin to secure the solvent cup...

Страница 73: ...Hydraulic Section Repair C 2 16 Part 1102698 07 E 2019 Nordson Corporation Notes...

Страница 74: ...umn means the part cannot be ordered separately The Description column gives the part name as well as its dimensions and other characteristics when appropriate Indentions show the relationships betwee...

Страница 75: ...zinc 4 21 1021440 S ROD connecting piston 1 22 1021428 S PISTON air 8 inch carboxylated nitrile 1 23 1021441 S WASHER 0 38 x 2 00 x 0 06 in stainless steel 1 24 S SCREW low head socket 3 8 16 x 1 00 z...

Страница 76: ...d Air Valve Parts D 1 3 Part 1102698 07 E 2019 Nordson Corporation 25 1 19 27 19 27 30 3 12 2 13 14 15 14 16 13 12 17 18 19 32 33 34 24 23 22 21 20 35 36 26 28 29 27 31 4 26 26 26 4 5 Figure D 1 1 Air...

Страница 77: ...1 4 in NPT 3 13 342268 S SPACER threaded male female steel hex 6 32 x 1 in 2 14 981577 S SCREW pan head 6 32 x 1 in slotted zinc 2 15 972126 S CONNECTOR male elbow 6 mm tube x 1 8 in unithread 3 16 9...

Страница 78: ...r and Air Valve Parts D 1 5 Part 1102698 07 E 2019 Nordson Corporation 1 2 3 8 7 5 2 1 10 9 8 9 9 8 9 8 9 8 4 3 3 4 3 8 11 6 12 12 12 13 14 15 15 15 18 19 19 16 18 20 17 17 16 18 Figure D 1 2 Air Valv...

Страница 79: ...IT 3 way valve 1 Air Valve T Seal Kit See Figures D 1 2 Item Part Description Quantity Note 1029057 KIT T seal 1 A 3 S O RING 4 5 S O RING 2 8 S SEAL T 6 NOTE A The air valve T seal kit may include an...

Страница 80: ...VE threadlocking Loctite Removable 242 1 900349 LUBRICANT TFE grease 0 75 oz tube MagnaLube G 1 Air Motor Accessory Group Item Part Description Quantity Note 1029320 ACCESSORY GROUP air motor PermaFlo...

Страница 81: ...n Quantity Note 1030529 KIT muffler PermaFlo 1 1 4 in NPT 1 1 S MUFFLER PermaFlo 1 1 4 in NPTF fitting 2 2 S SCREW socket head 1 4 20 x 0 50 in stainless steel 4 3 S WASHER lock split 1 4 in stainless...

Страница 82: ...ans the part cannot be ordered separately The Description column gives the part name as well as its dimensions and other characteristics when appropriate Indentions show the relationships between asse...

Страница 83: ...sure PermaFlo 815 1 C 7 S O RING PTFE 3 109 x 3 387 x 0 139 in 2 B 8 1023738 S HOUSING pressure hydraulic PermaFlo 815 1 9 S O RING 341 Buna N 70 duro 1 B 10 1024235 S CAGE ball siphon PermaFlo 815 1...

Страница 84: ...Hydraulic Section Parts D 2 3 Part 1102698 07 E 2019 Nordson Corporation 1 3 4 5 6 7 8 9 7 10 11 12 13 14 2 2 UPPER PACKING LOWER PACKING Figure D 2 1 Hydraulic Section with Standard Packings...

Страница 85: ...re PermaFlo 815 self adjusting 1 C 7 S O RING PTFE 3 109 x 3 387 x 0 139 in 2 B 8 1023738 S HOUSING pressure hydraulic PermaFlo 815 1 9 S O RING 341 Buna N 70 duro 1 B 10 1024235 S CAGE ball siphon Pe...

Страница 86: ...draulic Section Parts D 2 5 Part 1102698 07 E 2019 Nordson Corporation 1 3 4 5 6 7 8 9 7 10 11 12 13 14 2 2 UPPER PACKING LOWER PACKING Figure D 2 2 Hydraulic Section with Type D Self Adjusting Packin...

Страница 87: ...re PermaFlo 815 self adjusting 1 C 7 S O RING PTFE 3 109 x 3 387 x 0 139 in 2 B 8 1023738 S HOUSING pressure hydraulic PermaFlo 815 1 9 S O RING 341 Buna N 70 duro 1 B 10 1024235 S CAGE ball siphon Pe...

Страница 88: ...draulic Section Parts D 2 7 Part 1102698 07 E 2019 Nordson Corporation 1 3 4 5 6 7 8 9 7 10 11 12 13 14 2 2 UPPER PACKING LOWER PACKING Figure D 2 3 Hydraulic Section with Type F Self Adjusting Packin...

Страница 89: ...MWPE 10 S ADAPTER male PermaFlo 815 2 Type F Standard Packing Kit Included in the 1065204 pump with 1074995 hydraulic section Part Description Quantity Note 1060457 KIT packing Type F PermaFlo 815 1 S...

Страница 90: ...er of shims varies depending on stack height of assembly Do not add or remove shims from upper or lower assemblies AR As Required Type F Self Adjusting Packing Conversion Kit Optional packings can be...

Страница 91: ...ather 2 059 x 2 928 x 0 083 4 S S RING V 2 054 x 2 936 PTFE 6 S S ADAPTER male PermaFlo 815 2 S S WASHER backup PermaFlo 815 self adjust 2 S S SPRING wave 2 3 4 x 2 1 8 in stainless steel 4 Service Ki...

Страница 92: ...phon check PermaFlo 815 1 11 900006 S BALL 440 stainless steel 1 50 in 100 1 12 S SEAT ball 1 50 in diameter 1 13 S O RING PTFE 2 050 x 2 256 x 0 103 in 1 Options Alignment Tool Part Description Quant...

Страница 93: ...Part Description Quantity Note 170120 ACCESSORY GROUP siphon stainless steel 1 1 972724 S CONNECTOR male 37 1 5 16 12 x 1 in stainless steel 1 2 1082907 S HOSE siphon 1 in ID 8 ft stainless steel 1 3...

Страница 94: ...1 5 16 12 x 1 in stainless steel 1 2 1029259 S TUBE FITTING 37 degree tee female 1 in NPT stainless steel 1 3 336843 S CONNECTOR male 1 2 x 1 in stainless steel 1 4 336842 S ADAPTER female 1 2 x 1 2...

Страница 95: ...Hydraulic Section Parts D 2 14 Part 1102698 07 E 2019 Nordson Corporation This page intentionally left blank...

Страница 96: ...3 LOWER HEAD 1021428 PISTON 1021440 CONNECTING ROD HEX NUT 1021508 STUD 941373 O RING 941080 O RINGS 1024892 COUPLER KIT KIT B HEX NUT 952101 U CUP 1021442 BACKUP PLATE LOCKWASHER SCREW Manual 1085458...

Страница 97: ...VE T SEAL KITS A B SPOOL KIT B O RING KITS A B BRASS SLEEVE O RING KITS A B END CAP SOCKET HEAD SCREWS SERVICE KITS KIT A 1029057 T SEAL KIT KIT B 1029058 SPOOL AND SEAL KIT O RING KITS A B 1 4 20 x 1...

Страница 98: ...ECK KIT PACKING KITS 1037841 TYPE L PACKING KIT UHMWPE LEATHER V RINGS 1060457 TYPE F PACKING KIT PTFE LEATHER V RINGS 1089172 TYPE F SELF ADJUSTING PACKING KIT PTFE LEATHER V RINGS 1602028 TYPE F SEL...

Страница 99: ...n designed and manufactured according to the Directives and standards norms described above Flammable Atmosphere Marking Ex h IIB T6 Gb Tech File Notified Body 0518 Sira UK DNV ISO9001 ATEX Quality No...

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